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Optimizing laser-based micro-cutting for PMMA microfluidic device fabrication: thermal analysis and parameter optimization

  • Mst. Nasima Bagum , Md. Ahsan Habib , Choudhury Abul Anam Rashed EMAIL logo , Md. Mehedi Hasan Kibria and Syeda Kumrun Nahar
Published/Copyright: January 9, 2024
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International Polymer Processing
From the journal International Polymer Processing Volume 39 Issue 2

Abstract

Laser processes have gained popularity in microfluidic device fabrication. This study aims to determine the optimal parameters for laser-based micro-cutting to achieve the desired width, depth, profile, and material removal, considering the thermal properties of PMMA. A CNC CO2 laser was used, and 29 trials tested various speed and power combinations. Two theoretical models based on trial results focused on depth and width. COMSOL Multiphysics FEA software estimated surface temperature. Theoretical depth estimation matched experimental data more accurately when the P/S ratio was below 0.15 and the scanning speed was set at 500 mm/s or 750 mm/s. At 500 mm/s, width estimation was most accurate, up to 30 W. At 750 mm/s, experimental width exceeded predictions. Material removal increased proportionally with increasing P/S ratio, but beyond a threshold of 0.15, material removal remained nearly constant despite rising heat input. Laser-cut track shape varied, resembling a ‘U’ at lower and a ‘V’ at higher ratios. The groove shape transitioned from ‘U’ to ‘V’ when the temperature surpassed 1200 K. A V-shaped groove required a temperature exceeding 1500 K. Optimization confirmed a microchannel depth of 0.197 mm, width of 0.256 mm, and ‘U–V’ channel shape achievable at 30 W and 200 mm/s scanning speed, with a surface temperature of 1325 K.

Keywords: PMMA; CO2 laser; COMSOL multiphysics; surface temperature; width and depth
Corresponding author: Choudhury Abul Anam Rashed, Department of Industrial and Production Engineering, Shahjalal University of Science and Technology, Sylhet-3114, Bangladesh, E-mail:

Acknowledgments

The authors are thankful to the Research Centre, Shahjalal University of Science and Technology.

  1. Research ethics: Not applicable.

  2. Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission.

  3. Competing interests: The authors state no conflict of interest.

  4. Research funding: Research Centre, Shahjalal University of Science and Technology, Project ID: AS/2022/1/41.

  5. Data availability: Not applicable.

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Received: 2023-07-04
Accepted: 2023-12-04
Published Online: 2024-01-09
Published in Print: 2024-05-27

© 2023 Walter de Gruyter GmbH, Berlin/Boston

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https://doi.org/10.1515/ipp-2023-4408
Keywords for this article
PMMA; CO2 laser; COMSOL multiphysics; surface temperature; width and depth

Articles in the same Issue

  1. Frontmatter
  2. Research Articles
  3. Investigation of the effects of water uptake on the mechanical properties of wood dust particle filled Prosopis Juliflora reinforced phenol formaldehyde hybrid polymer composites
  4. Experimental investigation on mechanical and tribological analysis of pineapple leaf (Ananas comosus) and sisal (Agave sisalana) fibers reinforced hybrid epoxy composites
  5. An experimental study of weave pattern effect on the mechanical and dynamic behavior of composite laminates
  6. Structuring step dependent characteristics in joining using pin-like structures in the vibration welding process
  7. Fabrication of expandable graphite and soybean oil-based synergistic modified polyurethane foam with improved thermal stability and flame retardant properties
  8. Fabrication of electrospun nanofiber from a blend of PVC and PHB
  9. Investigation of mechanical and tribological performance of wood dust reinforced epoxy composite under dry, wet and heated contact condition
  10. Multi-layer co-extrusion blow molding
  11. Predicting part quality early during an injection molding cycle
  12. Optimizing laser-based micro-cutting for PMMA microfluidic device fabrication: thermal analysis and parameter optimization
  13. Preparation of PVDF/PVA composite films with micropatterned structures on light-cured 3D printed molds for hydrophilic modification of PVDF
  14. Evaluation of thermal contact resistance of molten resin–mold interface during high-thermal-conductivity polyphenylene sulfide filling in injection molding
  15. Effect of sinusoidal pulsating speed enhancement on the mixing performance of plastics machinery
  16. Experimental investigation on the mechanical and wear behavior of epoxy/Indian almond/peepal hybrid composites
  17. Exploration of the thermal and mechanical characteristics of polymethyl methacrylate-based copolymers: implications for wind turbine blades applications
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